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Beta RR 4T-250, Workshop Manual

The Beta RR 4T-250 Workshop Manual is a comprehensive guide offering detailed instructions and diagrams to assist in servicing and repairing your Beta RR 4T-250 dirt bike. Easily accessible for free download at manualshive.com, this essential manual ensures optimal performance and longevity for your off-road adventures.

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5

10 - Braking system 

Release 00 Date 02/2005

Replacing the front brake pads

To replace the brake pads, follow these steps: 

– Push the brake caliper towards the disc so that the pistons

can reach their base position. 

– Loosen grub screw 

A

.

– Pull out pin 

B

while supporting the two brake pads as shown

in the figure. 

– Remove the pads taking care not to drop the leaf spring lo-

cated underneath. 

– To refit the parts, follow the reverse procedure. When fitting

the brake pads, ensure that the leaf spring is properly posi-
tioned.

WARNING: 

Always keep the brake disc free from oil and

grease as these substances greatly reduce the braking
action.

Every time the braking system is serviced, operate the brake
lever to bring the pads into contact with the disc, restore the cor-
rect pressure point and ensure proper operation of the braking
system.

Replacing the front brake caliper pistons

Loosen the two screws 

C

and remove the brake caliper. Re-

peatedly pull the brake lever. In these conditions, without the
brake pads in place, the pistons will come out of their seats, al-
lowing the pistons and the related oil seals to be removed. Re-
place the parts with those contained in the spare kit. 

Subsequently replenish and bleed the system (see Chap-
ter 4 

Maintenance

). Only use DOT 4 or DOT 5.1 oil.

A

B

C

Summary of Contents for RR 4T-250

Page 1: ...WORKSHOP MANUAL RR 4T 250 400 450 525 ...

Page 2: ...lly plan the repair so as to avoid wasting time in obtaining spare parts preparing tools etc Gain access to the parts to be repaired by performing on ly the operations that are strictly necessary For best re sults always follow the removal procedures described in this manual Note Betamotor is committed to constantly improving its prod ucts For this reason there can be slight differences be tween t...

Page 3: ...c tools 3 Tightening torques Specifications Recommended products 4 Maintenance 5 Bodywork and fittings 6 Engine 7 Carburettor 8 Front suspension wheel 9 Rear suspension wheel 10 Braking system 11 Electrical system Workshop manual RR 4T 250 400 450 525 ...

Page 4: ...MBOLS Chap 1 8 CONVENTION Chap 1 9 SAFETY Chap 1 10 Carbon monoxide Chap 1 10 Petrol Chap 1 10 Engine oil Chap 1 10 Coolant Chap 1 10 Brake fluid Chap 1 11 Threadlocking fluid Chap 1 11 Shock absorber nitrogen Chap 1 11 Battery Chap 1 11 Hot parts Chap 1 11 NOTES Chap 1 12 TABLES OF CONTENTS TABLE OF CONTENTS OF EACH CHAPTER Chap 1 12 CONTENTS OF EACH CHAPTER Chap 1 12 OPERATING SPECIFICATIONS Cha...

Page 5: ... tightening by rotating the part by a predetermined angle e g 30 PURPOSE OF THE MANUAL This manual is chiefly intended for qualified Betamotor dealers and mechanics A mechanic should not expect to find all the information he requires in a manual Anybody who uses this manual should have a working knowledge of the princi ples of mechanics and of motorcycle repairing techniques Performing repairs or ...

Page 6: ...t the same time Piston piston rings and piston pins Valves valve springs valve cotters caps and thrust washers Valve guides with related valves springs caps valve cotters and thrust washers Crankshaft bearings Any part subject to even wear To keep the engine in perfect running order ensure that all fits are within the prescribed tolerances A close fit can lead to seizure as soon as the moving part...

Page 7: ...Date 02 2005 CONVENTION In order to clarify the left right convention used in this manual a diagram of the vehicle and engine are provided below with an indication of how the two sides are referred to in the manual Rh Rh Lh Lh FouP5troke ...

Page 8: ...cable laws Avoid disposing of spent oil in the environment Keep out of the reach of children Coolant Under certain circumstances the ethylene glycol contained in the coolant is flammable and its flame is invisible Should the ethylene glycol ignite its flame though invisible could cause serious burns Avoid bringing the coolant into contact with hot parts as these could ignite it The coolant ethylen...

Page 9: ...n through the inflating valve Only use nitrogen to pressurize the shock absorber Un stable gases can explode and cause burns To prevent the risk of explosions and burns avoid keep ing the shock absorber close to flames or heat sources Keep out of the reach of children Battery The battery produces explosive gases Keep it away from sparks flames and cigarettes Only recharge it in well ventilated pla...

Page 10: ...ENTIFICATION The frame number is stamped on the right side of the head tube The engine number is stamped on the upper crankcase half next to the swingarm ZD3 E1 XX XXXXXXXXXX Manufacturer s data Vehicle model Version 00 250 cc 01 400 cc 02 450 cc 03 525 cc The following is an example of frame number format 1 frame number ...

Page 11: ...rings 1 compression ring 1 scraper ring Lubrication 2 oil pumps Engine oil completely synthetic oil of known brands Motorex Cobra 15W40 Oil quantity 1 25 litres Primary drive cylindrical gears with straight teeth 33 76 teeth Clutch wet multiplate Transmission with front coupling 6 speed 6 speed 6 speed 6 speed Gear ratios 1st 14 38 1st 14 34 1st 14 34 1st 14 34 2nd 16 36 2nd 17 31 2nd 17 31 2nd 17...

Page 12: ...900B Main jet 160 178 178 Jet needle OBEKT OBDVR OBDVT Idling jet 42 42 42 Main air jet 200 200 200 Idling air jet 100 100 100 Needle valve position 3 3 3 Starting jet 85 85 85 Fuel mixture adj screw open by 0 75 turns 1 25 turns 1 25 turns Throttle valve 15 15 15 Power reduction throttle valve stop throttle valve stop throttle valve stop Pump diaphragm stop 858 2 15 mm 858 2 15 mm 858 2 15 mm ...

Page 13: ...free wheel socket head screw M6 Loctite 646 16 N m Primary drive gear hexagonal nut M20x1 5 Loctite 243 150 N m Countershaft gear socket head screws M6 Loctite 243 8 N m Clutch hub hexagonal nut M18x1 5 Loctite 243 150 N m Clutch spring flange screws M6 8 N m Gear selector socket head screw M6 Loctite 243 10 N m Selector lever flange screw M5 Loctite 243 6 N m Timing chain stretcher chain guide ch...

Page 14: ...er 88 926 88 956 mm size I fit 0 054 0 096 mm size II fit 0 056 0 099 mm wear limit 0 12 mm Piston 525 size I diameter 94 932 94 960 mm size II diameter 94 940 94 968 mm size I fit 0 050 0 070 mm size II fit 0 044 0 085 mm wear limit 0 12 mm Luce segmento compression ring max 0 80 mm scraper ring max 1 00 mm Valves width of sealing surface intake max 1 50 mm width of sealing surface exhaust max 2 ...

Page 15: ...255 mm with floating caliper Rear brake Steel disc Ø 240 mm with floating caliper Brake discs Wear limit 0 4 mm Front tyre 90 90 21 Tyre pressure off road 1 0 bar Tyre pressure road use 1 5 bar Rear tyre 140 80 18 Tyre pressure off road 1 0 bar Tyre pressure road use 1 8 bar Fuel tank capacity 8 5 litres including 1 litre reserve Chain 135 ZRDK 007 Bulbs Headlight 12V 25 25W Parking light 12V 3W B...

Page 16: ...e nut M20x1 5 CH27 90 N m Swingarm pin hexagonal nut M16x1 5 CH19 100 N m Handlebar clamp screws M8 CH10 20 N m Handlebar support screws M10 TCEI Loctite 243 40 N m Upper shock absorber screw M10x1 25 Loctite 243 80 N m Lower shock absorber screw M12 Loctite 243 80 N m Chain sprocket screws special screw M8 10 9 Loctite 243 25 30 N m Brake pedal screw M8 CH10 Brake pedal ball joint screw M6 Loctit...

Page 17: ...suspension K Frame bolts nuts and oil line T T Chain tensioning K K K Check and adjust clean lubricate or replace as necessary C Clean R Replace renew T Tighten RECOMMENDED LUBRICANTS To keep the vehicle in perfect running order and prolong its life we recommend using the products listed in the table be low PRODUCT TYPE SPECIFICATIONS MOTOREX COBRA 15W40 ENGINE OIL alternatively SHELL ADVANCE ULTR...

Page 18: ...d When the engine is cold the oil should reach the lower edge of sight A When the engine is hot the oil should reach the upper edge of the sight If necessary top up with engine oil WARNING An insufficient quantity of engine oil or the use low quality oil lead to early engine wear Changing the engine oil and the oil filter Before performing this operation remove if present lower bumper A after unsc...

Page 19: ... fitted into hexagonal head screw 3 next to the engine number Remove the screw with the oil unit thoroughly clean the components and blow them with low pressure com pressed air Check the O rings for damage and if necessary re place them Fit long oil unit 4 using a 300 mm spanner as shown in the fig ure then insert the spanner through the opening in the hole on the opposite side of the crankcase Pu...

Page 20: ...two oil filter cas ings with engine oil Fit the long filter unit in the front and the short filter unit in the back of the crankcase Grease the oil filter cover O rings and fit covers 4 Fit screws 2 and tighten them to 6 N m Tighten screw 1 to 8 N m Lift up the vehicle Remove screw fastening 5 from the clutch cover and pour in 1 25 litres of the recommended engine oil see table in Chapter 3 WARNIN...

Page 21: ...id is highly corrosive Take care not to drip it onto the paintwork Bleeding the front brake To bleed air from the front brake circuit follow these steps Remove rubber cap B from valve C Open the brake fluid reservoir cap Insert one end of a small tube into valve C and place the oth er end in a container Unscrew valve C while pulling the lever and repeatedly pull the brake lever until the oil comes...

Page 22: ...ve Take care not to drip onto the paintwork Bleeding the rear brake To bleed air from the rear brake circuit follow these steps Remove rubber cap E from valve F Unscrew the brake fluid reservoir cap Insert one end of a small tube into valve F and place the oth er end in a container Unscrew valve F while operating the pedal and repeatedly actuate the brake pedal until the oil comes out in an uninte...

Page 23: ...lacement of the brake pads can result in poor braking and lead to brake disc damage Checking the rear brake pads To check the wear of the rear brake pads visually inspect the caliper from behind The lining on the visible ends of the two brake pads should be at least 2 mm thick Should the lining be thinner immediately replace the brake pads NOTE Perform the check at the intervals specified in the M...

Page 24: ...e clutch it is first necessary to remove the clutch pump cover Remove the two screws 1 and take off cov er 2 together with the rubber bellows Remove the breather valve from clutch pump cylinder 3 and replace it with the bleed ing syringe filled with SAE 10 hydraulic fluid Inject fluid until it comes out with no air bubbles from clutch pump hole 4 Ensure that no fluid flows over After completing th...

Page 25: ...amping screws D and E Remove lower plug F and upper plug A pay attention to the spring Allow the oil to drain completely from the fork leg Screw on lower plug F again Pour in fresh oil of the type specified in the table in Chapter 3 Screw on upper plug A again Tighten screw D then screw E and then screw D again Workshop manual RR 4T 250 400 450 525 B C D E F A ...

Page 26: ...e to remove any excess oil so as to prevent dripping WARNING Do not clean the filter in foam containing petrol or petroleum as these substances may corrode it Do not clean the filter with hot water Do not start the engine if the air filter is not in place dust and dirt getting into the engine could cause damage and excessive wear If necessary also clean the inside of the filter casing When refitti...

Page 27: ...ck simply remove the spark plug cap and un screw the spark plug using the spanner provided Carefully clean the electrodes using a wire brush Blow the spark plug with compressed air to prevent any residues from getting into to engine Using a thickness gauge check that the spark gap is 0 6 0 7 mm If necessary correct the distance by bending the earth electrode Also check that the insulator is not cr...

Page 28: ...ase Memorize this position Now slow ly turn the mixture adjusting screw anticlockwise until the en gine speed starts to decrease again Choose the point be tween these two positions where the idle speed is higher Should the engine speed increase considerably reduce it to the standard level and repeat the above procedure NOTE Failure to successfully complete the above procedure may be due to an idli...

Page 29: ...lean any excess fuel with a rag Materials soaked in fuel are also highly flammable In case of ingestion or contact with sensitive body parts immediately seek medical attention Dispose of fuel in accordance with the law Coolant Check the coolant level when the engine is cold Follow these steps Unscrew cap A and visually check the level of the coolant When the engine is cold the liquid should be abo...

Page 30: ...on Tighten counternuts A on both fork arms Tighten nut 1 Chain wear Carefully follow the procedure described below to check the wear of the chain Change into neutral pull up the upper chain stretch with a force of 10 15 kg see figure Now measure the length of 18 links on the lower chain stretch If the measurement is equal to or greater than 272 mm replace the chain Chains do not always wear out ev...

Page 31: ...sition Shock absorber Adjusting the hydraulic compression damping high low speeds The shock absorber can be adjusted for both high and low speeds The expressions high speed and low speed refer to the move ment of the shock absorber not to the speed of the vehicle The low and high speed adjustments affect the behaviour of the shock absorber during slow and fast compression respectively Low speed ad...

Page 32: ...multimeter 10 12 hours after the activation check that the volt age is greater than 12 6 V If it is lower recharge the battery Depending on the recharger that is available recharge the bat tery using one of the following procedures Constant voltage charge the battery with a voltage of 14 4 15 V for about 12 hours 10 12 hours after the charging is com plete measure the voltage as previously describ...

Page 33: ...receiving the last pulse from the sensor The counter associated with this parameter can be reset by pressing button C or D for about 3 seconds while the LAP function is activated until 00 00 is displayed Resetting the LAP function also resets the TD parameter The LAP func tion can be reset both while riding and when the vehicle is stationary Total mileage counter function TOD T 3 and Vel 0 enters ...

Page 34: ... complete press the button for about 3 seconds while the least significant digit is selected to return to the standard operating mode If the pa rameter reaches 000 0 the system sets it to 999 9 After en tering the setting menu if the button is not pressed for 20 seconds the system will automatically return to the standard operating mode Once in the setting menu if the vehicle moves off Vel 0 the s...

Page 35: ...ode button for about 3 seconds while the cor responding value is selected will return the system to the standard operating mode Installing the instrument panel The default circumference value is 2154 mm the units for speeds and distances are km h and km respectively The de fault setting for the number of pulses is 1 pulse per wheel turn To change any one of these parameters use the pro cedure desc...

Page 36: ... as de scribed below Removing the saddle Remove the two fixing screws A one on each side lift the sad dle as shown in the figure and pull it back and off the vehicle Removing the rear mudguard Remove the two fixing screws B and then the two screws C and D from under the rear mudguard 5 Bodywork and fittings Release 00 Date 02 2005 A B C C ...

Page 37: ...panels In addition to fastening the rear side pan el the upper screw also fixes the saddle Removing the right hand side bumper Unscrew the six fixing screws G remove the plastic clamp and take off the right hand side bumper if present Removing the left hand side bumper Unscrew the four fixing screws H remove the two plastic clamps and take off the left hand side bumper if present Workshop manual R...

Page 38: ...brace fixing screw M from under the mudguard Finally remove the two brace fixing screws N from the top of the brace Removing the fork covers Unscrew the eight fixing screws P five on the left side and three on the right side and remove the fork covers 5 Bodywork and fittings Release 00 Date 02 2005 L M M P ...

Page 39: ...6 Removing the headlight grille Release the two rubber bands Q as shown in the figure pull out the headlight and remove grille R Workshop manual RR 4T 250 400 450 525 Q R ...

Page 40: ...addle by pulling it towards the back of the vehicle Removing the fuel tank To remove the tank together with the deflectors unscrew the left hand and right hand screws fixing it to the radiator Remove the central screw as shown in the figure and disengage the tank Close the fuel cock remove the fuel line and take off the reser voir 5 6 Engine Release 00 Date 02 2005 ...

Page 41: ...ws shown in the figure Remove the spring that fastens the silencer to the exhaust pipe Be careful to avoid injury from the spring Draining the cooling system Place a container as shown in the figure to collect the coolant Unscrew drain screw 1 on the cylinder front Remove the radiator cap in the upper part of the system and al low the coolant to drain completely Refit the drain screw using if nece...

Page 42: ...own in the figure and re move the lower pipe Removing the horn Remove the horn and the related bracket so as to facilitate the removal of the plastic bumper Loosen the two screws 1 and remove the left hand radiator Right hand radiator cylinder connecting pipe Remove the clamp shown in the figure and disconnect the right hand radiator lower pipe from the cylinder 7 6 Engine Release 00 Date 02 2005 ...

Page 43: ...nnect all the electrical connections cutting the wire clamps where necessary Tipping over the rear frame It is now possible to overturn the rear frame towards the front of the vehicle To avoid scratching the rear mudguard place a soft cloth over the handlebars Disconnecting the rear brake pump Unscrew the two screws 1 to disengage the rear brake pump from the frame 8 Workshop manual RR 4T 250 400 ...

Page 44: ...ing the rear shock absorber Disengage the shock absorber from the frame as shown in the figure Removing the exhaust pipe It is now possible to remove the exhaust pipe by pulling it to wards the front of the vehicle Removing the drive chain Find the split link move it onto the sprocket and remove the re tainer as shown in the figure Undo the chain and remove it 9 6 Engine Release 00 Date 02 2005 ...

Page 45: ...ed Removing the rear end The swingarm assembly can now be removed from the vehicle Removing the throttle twist grip assembly When the carburettor needs to be removed it is advisable to re move the throttle twist assembly from the handlebars Removing the carburettor Detach the sleeve that connects the cylinder to the carburettor and remove the carburettor together with the cables and the previously...

Page 46: ...ery pipe from the pump Removing the front sprocket casing Unscrew screw 1 and screw 2 on the opposite side Removing the clutch pump assembly Remove the clutch assembly without disconnecting the pipe so as to avoid having to fill and bleed the system again 11 6 Engine Release 00 Date 02 2005 2 1 ...

Page 47: ... the upper engine frame pivot pin Removing the kickstart Loosen the screw shown in the figure and remove the kickstart Removing the engine from the frame Remove the engine from the frame extracting it from the left side Place the engine on special tool 3625132 12 Workshop manual RR 4T 250 400 450 525 ...

Page 48: ... ring pliers see figure to pull out the oil filters WARNING There may be an outflow of residual oil dur ing this operation Removing the front sprocket Remove flange screw 5 together with the spring Remove the rear sprocket from the driven shaft Remove the distance ring from the driven shaft NOTE If the transmission and the clutch are in working order it is possible to shift into gear to lock the d...

Page 49: ...Removing the clutch Unscrew all clutch cover screws and remove the cover with its gasket Remove the two centring bushes from the crankcase To prevent the clutch plates from jamming when the clutch springs are released loosen the screws following a crosswise pattern Remove the pressure plate with the screws spring bracket and clutch springs Remove thrust head 1 Remove all the lined and steel plates...

Page 50: ...il the crankshaft screw is inserted in the related opening in the crankshaft Tighten the crankshaft fixing screw to 10 N m Pulling out the flywheel Unscrew the two screws 3 and remove the pick up from the crankcase Fit the puller and pull out the flywheel using the protective cap Remove the key from the crankshaft NEVER HIT THE FLYWHEEL WITH A HAMMER OR AN OTHER TOOL AS THIS COULD CAUSE THE FLY WH...

Page 51: ...ving shaft 2 1 4 3 Remove the two needle roller bearings 4 and the support washer Removing the oil pump Unscrew the two screws 5 and remove the oil pump cover Remove roller 6 inner rotor 7 and outer rotor 8 from the oil pump casing Remove oilway screws 9 e 10 with the related seal rings and then remove the oil line 3 3 4 6 7 8 9 10 ...

Page 52: ...screws and remove water pump cover 2 with the related gasket Unscrew all screws 3 on the cylinder head top Using a plastic mallet carefully hit area A in an upward direc tion and remove the cylinder head top Removing the cylinder head the cylinder and the piston Remove screw 4 with the seal ring and the compression spring Unscrew the two screws and pull the chain stretcher out of the cylinder 1 2 ...

Page 53: ...e clamp into each chain end Remove the camshaft from the cylinder head Remove the three screws 1 NOTE There is no need to remove these three screws if the cylinder and the cylinder head require no servicing The cylinder and the cylinder head can be removed together without having to replace the cylinder head gasket The screw on the timing chain side is fitted with a copper seal ring 6x10x1 When re...

Page 54: ... the piston Removing the timing chain and gear Loosen the two screws 1 and remove chain guard 2 Remove the timing chain Remove screws 3 and 4 pull the chain stretcher and the chain guide up and out of the crankcase Remove Seeger ring 5 Fit the puller and remove the timing gear from the crankshaft 1 2 4 3 5 1 ...

Page 55: ...ess the kickstart spring and unfas ten it WARNING TAKE CARE TO AVOID INJURY DUE TO THE RE LEASE OF THE KICKSTART SPRING Remove the kickstart shaft the starter coupling the spring and the washer from the crankcase Push back the guide plate and pull out the gear shaft and thrust washer 5 from the crankcase Remove screw 6 and the gear selector Unscrew screw 7 and remove the selector lever together wi...

Page 56: ... BEARING THE CAPTION LEFT HAVE A LEFT HAND THREAD THOSE WITH NO INSCRIPTION HAVE A RIGHT HAND THREAD Pull out from the crankcase the oil pump shaft complete with the roller inner rotor 3 and outer rotor 4 Remove the two opposed screws 5 Fit the puller and remove the primary torque gear from the crankshaft Loosen the crankshaft fixing screw Unscrew all thirteen crankcase screws 1 4 3 5 2 ...

Page 57: ...kcase half with its gasket Remove the two centring bushes from the crankcase and fix the right hand crankcase half in the stand Remove thrust washer 1 O ring 2 and inner ring nut 3 Remove the two fork guide rods 4 with the four springs from the crankcase and turn the gearshift forks to one side Remove desmodromic mechanism 5 Remove gearshift forks 6 During the removal ensure that gearshift bushes ...

Page 58: ... marks on the countershaft and the crankshaft are aligned In this position the crankshaft can be removed from its seat Remove the crankshaft Clean all the parts check them for wear and replace as nec essary NOTE When the engine is overhauled it is advisable to replace all gaskets oil seals O rings and bearings ...

Page 59: ...utside to the correct le vel with the open side facing inward Driven shaft oil seal 5 Fit the new oil seal pushing it from the outside to the correct le vel with the open side facing inward Countershaft ball bearing 6 Using a bearing puller extract the bearing from the crankcase half Insert the new bearing and push it to its abutting end Desmodromic mechanism ball bearing 7 At a temperature of app...

Page 60: ... bearing 3 Using a suitable drift push in the bearing from the outside Fit the new bearing pushing it from the inside to its abutting end NOTE Driving shaft ball bearing 3 is fastened by a screw Ap ply Loctite 243 to the screw thread and tighten to 5 N m Driven shaft ball bearing 4 Using a suitable drift push in the bearing from the outside Fit the new bearing pushing it from the inside to its abu...

Page 61: ...needle roller bearing from the outside Insert the new bearing pushing it in from the outside until it is flush When the crankcase half has cooled down ensure that the bearing is securely seated Kickstart release plate 5 When replacing the release plate apply Loctite 243 to the two screws and tighten to 8 N m Oil pump casing 6 should bear no signs of scoring or seizure Ensure that the passages of a...

Page 62: ... 5 mm the by pass valve opening pressure is reduced This entails a decrease in the oil pressure and thereby greater wear Blow all the oil channels with compressed air and check that the passages are clear Clutch cover Kickstart shaft oil seal 3 Remove the old oil seal with a screwdriver Fit the new oil seal and push it to its abutting end Crankshaft oil seal 4 Remove the old oil seal with a screwd...

Page 63: ...UT OF PO SITION THE CONNECTING ROD BEARING WILL RE CEIVE LITTLE OR NO OIL AND WILL CONSEQUENTLY BE DAMAGED If the crankshaft is to be reused be sure to check the offset of the shaft sections Place the crankshaft on a roller equalizer or similar equipment and use a comparator to measure the offset at the ends of the shaft sections Offset of shaft sections 0 08 mm Check the radial and axial plays of...

Page 64: ...haft gear to the crankshaft so that mark C is in the coupling shaft area Fit the fixing screws and tighten to 8 N m Before fitting a new inner collar heat the special tool again to about 150 C fit it with the inner collar and immediately push it onto the shaft section Allow the inner collar to cool down for about 30 seconds and then using a suitable tube hit the inner collar until it is seated pro...

Page 65: ...9 000 89 012 mm size II cylinder 89 013 89 025 mm Cylinder diameter 525 size I cylinder 95 000 95 012 mm size II cylinder 95 013 95 025 mm Cylinder size 1 is stamped on the cylinder side in front of the chain tunnel piston size 2 is stamped on the piston top The piston is measured on the skirt transversally to the piston pin as shown in the figure Piston diameter 250 size I piston 74 960 74 970 mm...

Page 66: ...iston rings and their gaps Insert the piston ring in the cylinder and align it with the piston approx 10 mm under the upper edge of the cylinder Using a thickness gauge measure ring gap A Compression ring max 0 80 mm Scraper ring max 1 00 mm If the measurements exceeds the above values check the wear of the cylinder and piston If wear is within the allowable limits replace the piston ring Checking...

Page 67: ...hange also replace the O rings Oil pump cover 3 Check the inside for signs of seizure caused by the oil pump rotors and if necessary replace Oil pump shaft 4 Place the shaft on a flat surface and check its offset Oil pump gear 5 Check the teeth for wear The roller seat should not be damaged Oil units 6 Clean the two oil units with low pressure compressed air O rings 7 Check their porosity and if n...

Page 68: ... rollers 8 Check that the rocker arm rollers can slide freely If any radial play is found replace the rocker arm Adjusting screws 9 The contact surfaces of the adjusting screws should be flat Decompressor shaft 2 Check the sliding of the decompressor shaft and its play in the support hole Replace O ring 11 Replacing O rings 10 Before reassembly carefully oil all the components Position the rocker ...

Page 69: ...aust flange 2 to gether with its gasket Using the specially designed tool remove the four valves The 250 cc model fits conical valves Used valves are to be reinserted in the same valve gui de To ensure this we recommend inserting the valves in a piece of cardboard in the same way they are fitted in the cy linder head see figure ...

Page 70: ...w no signs of hammering in The sealing surface should be at the centre of the valve seat The valve stem is chromium pla ted wear generally occurs on the valve guide Valve springs Visually check that the valve springs are not broken or worn Measure their length with a vernier caliper The minimum al lowable valve length is 39 20 mm for the outer valve springs and 36 45 mm for the inner valve springs...

Page 71: ... from decompressor shaft 7 while extracting the latter from the camshaft Unscrew the two screws 8 and remove camshaft gear 9 Using the puller remove ball bearing 10 from the camshaft Clean and check all components and if necessary replace them Camshaft Check the support points and the cams for signs of wear Replace ball bearings 5 and 10 Decompressor shaft 7 Check the play of the shaft in the supp...

Page 72: ...inder head with the aid of the two M3 threaded holes 4 without removing the cylinder head top 1 1 3 3 2 8 5 9 7 6 6 10 13 14 12 Preassembling the camshaft Apply Loctite 243 on the threads of the two screws 6 and fit camshaft gear 7 Tighten the screws to 28 N m Key ball bearing 5 with a socket punch Fit decompressor shaft 8 and spring 9 Preload the spring by approximately 1 2 turn and insert the sp...

Page 73: ... by the arrow so that the pressure pin no longer jams and then fully insert the pressure pin into the stretcher body 1 3 4 2 Valve gear control Thoroughly clean all the components and check them for wear Timing pinion 1 Check the teeth for nicks or signs of wear Chain stretcher shoe 2 Check for signs of sliding on the contact surface Chain guide 3 Check for signs of sliding on the contact surfaces...

Page 74: ...Seven cork discs 5 Minimum allowable thickness 1 7 mm 1 8 mm when new The cork discs must be flat Eight 1 0 mm middle discs 6 Ensure that the discs are flat and free from mechanical damage Replace as necessary Clutch hub 8 Check for damage and signs of wear Pressure plate 9 Check for signs of damage on contact surface A with the steel plate Clutch drum 10 Check the wear of thrust surfaces B of the...

Page 75: ...that the starter gear oil hole is clear Preassembling the kickstart shaft Clamp kickstart shaft 4 in a vice using protective jaws with its toothed end facing upwards Fit thrust washer 5 needle roller cage 6 and starter gear 1 with the stop teeth facing downwards Fit thrust washer 7 and Seeger ring 8 with the sharp edge fa cing upwards Fit dragging hub 9 taking care to align its groove with the ho ...

Page 76: ...Check wear at return points C Check the wear of selector return surface D if the surface is deeply worn replace the selector Check that guide pin E is firmly seated and not worn Gearshift mechanism Preassemble the shaft of the gearshift mechanism and measu re clearance F between selector 6 and the guide plate The play should be 0 40 0 80 mm Preassembling the shaft of the gearshift mecha nism Clamp...

Page 77: ...rings whenever the transmission is repaired Assembling the driving shaft Clamp the driving shaft in a vice with its grooved end facing downwards use pro tective jaws Carefully oil all the components before assembling them Fit needle roller cage 2 top it with 5th speed idler gear 1 with the front couplings fa cing upwards Insert thrust washer 3 25 2x32x1 5 mm and Seeger ring 4 with the sharp edge f...

Page 78: ...oved end facing downwards use pro tective jaws Carefully oil all components before assembling them Fit needle roller cage 2 and 2nd speed idler gear 1 on the driven shaft with the slot for the front couplings facing upwards Insert thrust washer 3 25 2x32x1 5 mm and Seeger ring 4 with the sharp edge fa cing upwards Fit 6th speed sliding gear 5 with the fork slot facing upwards Fit Seeger ring 6 and...

Page 79: ... ohmmeter take the following measurements NOTE The following measurements correspond to the nominal values only at a temperature of 20 C If the measured values differ considerably from the nominal va lues replace the stator Replacing the stator Loosen screw 4 and remove the fixing plate Unscrew the two screws 5 and remove the stator from the ignition cover Position the new stator in the ignition c...

Page 80: ...b 3 Remove the free wheel from the hub and check to see if there are any dents on contact surface A Thoroughly clean the free wheel hub Free wheel 4 Thoroughly clean the free wheel with petroleum and compressed air Check the free wheel segments for wear and oil it generously Free wheel gear 5 Fit the free wheel gear on the crankshaft and check the play If necessary replace the needle bushing Check...

Page 81: ...hub 5 laterally to detach it from the primary gear Fit a new free wheel hub on the primary gear Degrease the screw threads apply Loctite 648 to them and ti ghten the screws to 16 N m following a crosswise pattern Carefully oil free wheel 2 and insert it into hub 5 Using a pair of Seeger ring pliers insert the expansion ring in to the groove and ensure that it is properly seated Once the expansion ...

Page 82: ...shaft until mark A is at the front and then insert the countershaft into its bearing Ensure that crankshaft mark A is between the two countershaft marks B Fitting the gearbox and the gearshift mechanism Turn the engine onto one side Simultaneously insert driving shaft 1 and driven shaft 2 into their respective bearings Attach bushes 3 to the gearchange forks with a little grease Attach the four sp...

Page 83: ...nto its bearing Attach the gearshift forks to the desmodromic mechanism and fit the two fork guide rods 2 along with the springs Ensure that the following parts are fitted inner race of bearing 3 O ring 4 thrust washer 5 2 centring bushes in the crankcase 56 Workshop manual RR 4T 250 400 450 525 1 A 4 5 2 2 3 ...

Page 84: ...he screws and tighten them for the lengths of the screws refer to the diagram Check that all the shafts can move smoothly before and after tightening the crankcase screws to 10 N m Clamp the engine in the stand Accurately cut off the gasket that protrudes from the cylinder base and the sealing surfaces Check to see if the key is fitted to the crankshaft Carefully oil the free wheel and the needle ...

Page 85: ...If the selector plate has been removed it can now be eas ily refitted Fit oil pump gear 3 thrust washer 4 and safety washer 5 Check the smoothness of the oil pump shaft by turning the oil pump gear Using a cloth carefully clean the rest surface of the oil pump cover Position the inner and outer rotors in the crankcase so that the two centres A and B are placed next to each other The inner and oute...

Page 86: ...ogether with the thrust washer un til the selector comes into contact with the gear selector Push back the selector and push in the gear control shaft un til it stops Check that spring ends A touch crankcase dog B on the left and right sides Fit the gearchange lever and then insert all the gears in suc cession When changing gears turn the driving shaft then re move the gearchange lever again Fitti...

Page 87: ...ehind the release plate Attach the spring link to the starter spring apply Loctite 243 to the thread of screw 3 M6x12 preload the starter spring by turning it about 45 degrees clockwise fasten the spring link with the screw and tighten to 10 N m Position the starter spring so that the distance from the kick start shaft does not change Exercise extreme caution when fitting the spring as it could co...

Page 88: ...al tool see removal procedure fit flange nut 5 and tighten it to 150 N m Secure the flange nut with safety plate 6 as shown in the fig ure As a rule there is no need to heat a used clutch hub be fore fitting it Fitting the primary pinion nut Position the special tool as shown in the figure Degrease the crankshaft thread and apply Loctite 243 to it Fit flange nut 7 and tighten it to 150 N m Bring t...

Page 89: ... N m without forgetting the two bush es Fit the chain stretcher shoe locking the screw in the seat in the crankcase B NOTE AFTER TIGHTENING THE CHAIN STRETCHER SHOE ENSURE THAT IT CAN SLIDE FREELY Fit the timing chain so that the two stretches have the same length NOTA The timing chain can also be fitted after fitting the cylin der and the cylinder head Degrease the threads of the two screws 7 M5x...

Page 90: ...piston and remove the mounting ring WHEN FITTING THE CYLINDER TAKE CARE NOT TO BREAK THE OIL SCRAPER RING Fitting the cylinder head Check that the two centring bushes are properly seated in the cylinder Fit a new cylinder gasket with the inscription ALTO facing upwards and fit the cylinder head and the timing chain Oil the threads and the contact surfaces of the four flange screws and fit them alo...

Page 91: ...at the top dead centre using the crankshaft fixing screw Fit the timing chain on the camshaft gear and then fit a new chain joint 1 First fit the insert of the special tool as shown in the figure and then press the chain joint Fit the insert of the special tool as shown in the figure and riv et the chain joint The nailing of the chain coupling should be so strong that the cross section of the coup...

Page 92: ...s check and if necessary adjust the axial play of the rocker arms To this end insert a thickness gauge 1 0 05 mm between the terminal and the rocker arm Push in the terminal and tighten the screw next to the terminal Tighten the other screws to 10 N m following a crosswise pat tern Rocker arm axial play 0 02 0 10 mm Fit the fitting cap grease the O rings and fit the seal holder so that its abuttin...

Page 93: ...ve play A is measured between the valve stem and the ad justing screw when the engine is cold Cold valve play 0 12 mm NOTE IF THE PISTON IS NOT AT THE TOP DEAD CENTRE THE VALVES ARE ACTUATED BY THE ROCKER ARMS AND THE PLAY OF THE VALVES CANNOT BE PROPERLY AD JUSTED IN THAT CASE ROTATE THE CRANKSHAFT ONE MORE TURN AND THEN LOCK IT AGAIN After completing the adjustment tighten the counternuts to 11 ...

Page 94: ...Pushing with the clutch retainer tighten the flange nut to 60 N m Fitting the pick up and the ignition cover Position the pick up in the crankcase and insert cable guide 2 in the specially designed opening in the crankcase Degrease the thread of the two screws 3 M5x16 apply Loc tite 243 and tighten the screws to 6 N m Fit a new gasket and fasten the ignition cover with the four screws 4 and 5 Tigh...

Page 95: ...rews Tighten screws 7 to 10 N m following a crosswise pattern Ensure that the centring bushes are fitted in the crankcase Grease all the oil seals in the clutch cover and fix the clutch cover gasket with a little grease Take special care in ensuring that oil jet 8 in the crankcase is not blocked by the gasket Pour approximately 30 ml of engine oil in the crankshaft hole M6x35 M6x30 M6x30 M6x30 M6x...

Page 96: ...he O ring on the starter motor and insert the mo tor in the crankcase Fit the two screws 4 M6x20 and tighten them to 8 N m Oil distance ring 5 and slide it onto the driven shaft with the groove for the O ring facing inward Fit the chain sprocket with the high collar facing inward Degrease the flange nut thread apply Loctite 243 to it and tighten the screw with the spring washer to 60 N m NOTE Befo...

Page 97: ...m 4 15 N m 5 20 N m 0 C 32 F 15W 40 15W 50 10W 40 10W 50 API SG SH TEMPERATUR Remove the clamping screw from the clutch cover and pour in 1 20 litres of 10W 50 engine oil see table in Chapter 3 Tight ening torques Specifications Recommended products Replace the clamping screw and check the seal of the engine NOTE Check the engine oil level after reinstalling the engine on the vehicle WE RECOMMEND ...

Page 98: ...3 7 Carburettor Release 00 Date 02 2005 CARBURETTOR KEIHIN FCR M X 39 ...

Page 99: ... from the working area Always work in a well ventilated area Never use petrol as a cleaning solvent Handle petrol on ly if absolutely necessary Do not use petrol to clean compo nents that need to be blown with compressed air Keep out of the reach of children When refitting fit the carburettor to the sleeves and fasten it with the two hose clamps Ensure that the carburettor is fitted vertically in ...

Page 100: ...lean it of coarse dirt Loosen the two screws 1 and remove all breather pipes from the carburettor Remove the two screws 2 and remove the throttle valve cov er from the carburettor with the related gasket Remove screw 3 and pull the jet needle out of the throttle valve Remove screw 4 Pull up the throttle valve lever and remove the throttle valve complete with roller 5 and the throttle valve plate f...

Page 101: ...r with the nee dle valve Remove main jet 2 Loosen screw 3 and using a pair of pliers carefully remove the float needle valve support from the carburettor Unscrew idling jet 4 starting jet 5 and nozzle 6 Tighten mixture adjusting screw 7 until it stops taking note of the screw turns Unscrew the mixture adjusting screw and remove it together with the spring washer and O ring NOTE As a rule the sprin...

Page 102: ...e out of the car burettor Loosen the two screws and remove the suction pump and O ring 4 from the carburettor Unscrew choke idling jet 5 and choke main jet 6 Clean all the jets and the other components and blow them with compressed air Clean the carburettor body and blow all the ducts inside it Check the condition of all the gaskets and replace any dam aged ones 7 7 Carburettor Release 00 Date 02 ...

Page 103: ...ing the jet needle Ensure that the jet needle is not bent or worn Checking the float needle valve Check to see if the sealing surface of the needle valve presents any dimples There should be no dirt between the valve seat and the float needle Checking the throttle valve Throttle valve rollers 3 should rotate easily and have no flat ar eas Check that throttle valve plate 4 is not damaged 1 2 2 3 4 ...

Page 104: ...e sure it slides properly Also check if the knob engages properly Fit the spring the washer and the O ring on mixture adjusting screw 7 and tighten the screw until it stops Unscrew the mixture adjusting screw by the number of turns that was taken note of during disassembly Original carburettor adjustment see table in Chapter 3 Specifications Fit idling jet 8 starting jet 9 and the nozzle complete ...

Page 105: ...cing upwards and the spring in the pump casing Fit O ring 6 in the groove Fix seal ring 7 in the cover with a lit tle grease and fasten the cover with the three screws Fit the throttle sensor so that the flat area on the carburettor engages the throttle sensor slot and fasten it by means of screws 10 Pull up the throttle valve lever and insert the throttle valve along with roller 8 and the plate i...

Page 106: ...the jet needle and fasten it with screw 2 Position the throttle valve cover with the related gasket and fasten it with the two screws 3 Fasten the breather pipes with the two float chamber screws 4 11 7 Carburettor Release 00 Date 02 2005 2 1 3 3 4 4 ...

Page 107: ...y the resistance should vary evenly Removing and refitting the throttle sensor Unplug the throttle sensor and loosen screws 1 Remove the throttle sensor from the carburettor THROTTLE SENSOR RESISTANCE 4 6 kΩ 12 Workshop manual RR 4T 250 400 450 525 When fitting the throttle sensor ensure that the flat section of the throttle pin engages the throttle sensor slot Fit the two screws without tightenin...

Page 108: ...essful the problem may be due to an idling jet of unsuitable size a If the mixture adjusting screw is turned until it stops and the idle speed does not change a smaller idling jet is needed b If the engine stalls while the mixture adjusting screws is still open by two turns a larger idling jet is required It goes without saying that after replacing the jet the adjust ment will have to be restarted...

Page 109: ...3 8 Front suspension wheel Release 00 Date 02 2005 Four Stroke l ...

Page 110: ...g holder 19 Compression adjusting screw 21 Spring 24 Spring guide 25 Preload tube 28 Foot pad 30 Cartridge case 31 Inside rod 32 Pump rod 33 Fin pull off spring 34 Rebound piston fin 36 Pump piston 37 Rebound damping piston reeds 39 Upper sliding bush 41 Foot valve 43 Compression valve fin 45 Foot valve piston 46 Compression damping valve reeds 48 Cap 70 Wheel holder 71 Rebound adjusting screw 72 ...

Page 111: ...s replaced refer to the table of tightening torques in Chapter 3 Tightening torques Specifications Recom mended products Remove the leg protections the front mudguard and the mud guard grille see Chapter 5 Bodywork and fittings Unscrew the two screws 1 disconnect the caliper assembly re move the pipe from the fork and disconnect the speed sensor cable Unscrew the four screws on the left side and t...

Page 112: ...s from the head tube Checking the head tube seats Check the seats for wear If necessary remove them using a suitable drift For each seat use a drift and a hammer to alternately hit the grooves in the head tube to the left and right of the seat Use the drift from above to remove the lower seat Use the drift from below to remove the upper seat 6 Workshop manual RR 4T 250 400 450 525 1 2 ...

Page 113: ...grease Installation Manually press wiper seal 12 back into its seat 12 50 14 Air bleed screw NOTE This operation is to be performed with the fork installed on the vehicle and the fork legs fully extended front wheel off the ground Owing to the particular shape of the seal rings air getting into the fork legs during use may remain trapped and cause fork malfunctions Removal Using a cross tip screwd...

Page 114: ...ing 21 to allow a 19 mm spanner to be inserted in counternut 23 While holding counternut 23 in position with the 19 mm span ner use another 19 mm spanner to completely unscrew plug 48 48 31 20 21 32 25 Remove plug 48 spring guide cup 20 spring 21 and preload tube 25 Remove adjuster inside transmission rod 32 from the end of rod 31 Release fork leg 5 from the vice and turn it upside down over a sui...

Page 115: ...te its locking However the tool must on no account be turned but should only be used to hold the fork leg inside components in place Using the 21 mm socket wrench unscrew foot valve 41 Remove foot valve assembly 41 Remove shock absorber assembly 21 from fork leg 5 21 5 23 24 Unscrew and remove counternut 23 and remove spring guide 24 To be able to work on the pump it is first necessary to remove t...

Page 116: ...assembly to be removed from below NOTE The pump can be completely overhauled and adjusted Check ring 35 for wear 35 12 Separating the fork leg from the leg holder and removing the seal rings Using a small flat blade screwdriver remove wiper seal 12 Using the same screwdriver remove metal retaining ring 11 11 ...

Page 117: ...the bush slot Remove lower guide bush 8 cup 9 seal ring 10 retaining ring 11 and dust scraper 12 from the fork leg Do not reuse the removed seal rings and wiper seals 39 8 10 11 9 12 32 38 Overhauling and changing the adjustment of the cartridge and the foot valve Overhauling the cartridge rebound damping Removal Clamp the milled portion of rod 32 in a vice Depending on the type of nut used unscre...

Page 118: ...ng fin or fins 37 in the rod end The piston should be oriented so that the smaller holes face adjusting fins 37 Manually screw in nut 38 Clamp the milled part of damping rod 32 in a vice Using a suitable spanner 12 mm or 13 mm based on the nut used tighten nut 38 to the prescribed torque see table in Chapter 3 Tightening torques Specifications Recommend ed products 35 37 36 34 33 32 38 42 47 Overh...

Page 119: ... a vice the foot screw through spanner slot 47 Using a 13 mm spanner tighten nut 42 to the prescribed torque see table in Chapter 3 Tightening torques Specifica tions Recommended products 42 47 Reassembling the fork leg and the sheath Fitting the seal rings Never reuse any removed seal rings and wiper seals Be fore reassembly check the condition of the guide bush es If they are scored or scratched...

Page 120: ... into the sheath taking care to ensure that the upper guide bush does not receive damage Move the lower guide bush until it comes into contact with the sheath the cup and the seal ring Fit the specially designed inserter on fork leg 5 and use it to push seal ring 10 until the lower guide bush the cup and the seal ring are properly seated 10 5 11 Using a small flat blade screwdriver fit retaining r...

Page 121: ...d tip 29 into rod 32 so that the side with the spanner slot faces case 30 and the tip goes past wire groove F Fit wire 27 into groove F Bring tip 29 into contact with the retaining ring Insert foot pad 28 so that slotted holes for the passage of oil face the tip Insert upper nut 26 and screw it on tip 29 26 32 28 27 F 29 26 29 Holding nut 26 with an 18 mm spanner tighten tip 29 to the prescribed t...

Page 122: ... 13 Adding oil Push the sheath all the way up along the fork leg Prepare the oil to be poured into the fork leg in a measuring cup see table in Chapter 3 Tightening torques Specifications Recommended products Pour approximately 2 3 of the oil into sheath 13 then pump a few times to remove the air Pour in the rest of the oil Lower the leg holder on the fork leg until the wiper seal comes into conta...

Page 123: ...roper adjustment by turning adjusting screw R see table in Chapter 3 Tightening torques Specifications Recommended products 48 Reinstalling the fork on the vehicle Follow the reverse procedure to the removal observing the tightening torques specified in the table in Chapter 3 Tightening torques Specifications Recommended products To ensure proper operation of the fork fit the wheel on the fork by ...

Page 124: ...Before attempting to remove the rear suspension place the vehicle on a central stand with the rear wheel off the ground 3 9 Rear suspension wheel Release 00 Date 02 2005 ...

Page 125: ...ws and remove the rear sprocket from the wheel hub WARNING Important Follow these steps to properly tighten the rear sprocket Apply medium resistance threadlocking Loctite to the screw threads Using a torque spanner tighten the six sprocket locknuts to 25 30 N m Check the tightening by turning the six inside nuts with a hexagonal long arm CH13 spanner 400 500 mm All the nuts should be securely loc...

Page 126: ...products Removing the swingarm Disengage the swingarm from the rear brake line and from the caliper with its support bracket Unscrew the swingarm frame pin and the swingarm linkage pin Remove the swingarm Removing the shock absorber Unscrew pins 1 and 2 and unfasten the rear suspension link age Remove the upper shock absorber fastener 5 9 Rear suspension wheel Release 00 Date 02 2005 2 1 2 1 ...

Page 127: ...cks and thorough inspections are necessary especially if the vehi cle is used in competitions Visually check all the components and in particular the pump the pipes and the caliper Ensure that there are no leakages and that all the components are in good condi tion 3 10 Braking system Release 00 Date 02 2005 ...

Page 128: ... only be performed after emptying the system Avoid disposing of the fluid in the environment Dispose in accordance with the law Remove the pump and replace it with a new spare kit Subsequently replenish and bleed the system see Chap ter 4 Maintenance Only use DOT 4 or DOT 5 1 oil 4 Workshop manual RR 4T 250 400 450 525 1 ...

Page 129: ...brake disc free from oil and grease as these substances greatly reduce the braking action Every time the braking system is serviced operate the brake lever to bring the pads into contact with the disc restore the cor rect pressure point and ensure proper operation of the braking system Replacing the front brake caliper pistons Loosen the two screws C and remove the brake caliper Re peatedly pull t...

Page 130: ...disposing of the fluid in the environment Dispose in accordance with the law Remove right hand guard 1 if present Unscrew nut 2 to disengage the brake lever pump Remove the pump from below and replace it with a new one from the spare kit Subsequently replenish and bleed the system see Chap ter 4 Maintenance Only use DOT 4 or DOT 5 1 oil 1 2 ...

Page 131: ...sc so that the pistons can reach their base position Loosen grub screw A Pull out pin B while supporting the two pads see figure Remove the pads taking care not to drop the leaf spring above them To refit the parts follow the reverse procedure When fitting the brake pads ensure that the leaf spring is properly posi tioned Replacing the caliper pistons After removing the caliper and the brake pads ...

Page 132: ...2 Workshop manual RR 4T 250 400 450 525 Ve Ne 11 I I 41 Az R I I 1 Gi Rse Gi Rs F ve Ne Vi Vi r 11 1 IJ t sl o Go Bi Ne Ne Go Bi B b r b Ne Vi Ve fW Ne ____ l_ f I ...

Page 133: ...LH REAR INDICATOR WITH 12V 10W BULB 20 NUMBER PLATE LIGHT WITH 12V 5W BULB 21 REAR LIGHT WITH 12V 5 21Wh BULB 22 RH REAR INDICATOR WITH 12V 10W BULB 23 BATTERY POSITIVE TERMINAL 24 12V 4Ah BATTERY 25 DYNAMO 26 10A FUSE 27 EARTH BRAID 28 STARTING RELAY 29 STARTER MOTOR 30 BATTERY NEGATIVE TERMINAL 31 CONTROL UNIT 32 HV COIL 33 SPARK PLUG 34 REAR BRAKE LIGHT BUTTON 35 FRAME EARTH 36 12V 3W PARKING L...

Page 134: ... measure its charge Use a voltmeter to measure the voltage between the battery terminals voltage at rest Maximum tolerance of measuring instrument 1 per cent To obtain a correct measurement do not charge or discharge the battery for at least 30 minutes before performing the ope ration If the battery charge cannot be determined the battery can be charged for a maximum of 10 hours with 0 5 amperes a...

Page 135: ...ll container compartments are empty remove the con tainer from the battery Carefully close the filler openings with the cover NOTE After filling the battery allow it to rest for at least half an hour without charging it IMPORTANT WHEN FILLING A NEW BATTERY BE SURE TO FOLLOW THE DIRECTIONS PROVIDED IN THE ENCLOSED INSTRUCTION SLIP WHICH ALSO PROVIDES THE SAFETY RULES TO BE FOLLOWED FAILURE TO OBSER...

Page 136: ...n on the low beam Connect a voltmeter to the two battery connections Rev the engine to 5000 rpm and read the voltage Nominal value 14 0 15 0 V If the measured value differs considerably from the nominal va lue follow these step Check the plug between the stator and the regulator rectifier and the plug between the regulator rectifier and the wiring harness Check the stator Replace the regulator rec...

Page 137: ...rgency switch in on position Battery charge Main fuse Check if a spark is produced when the engine is started by fol lowing these steps Remove the spark plug cap Separate the spark plug cap from the ignition cable Keep the free end of the ignition cable about 5 mm for an earth connection When the starter motor is operated a bright electrical spark should be produced If the battery charge is very l...

Page 138: ...lectrical system The fuse has a capacity of 10 amperes WARNING Do not on any account fit a fuse of greater power or attempt to fix the damaged fuse Unsuitable servicing could cause dama ge to the entire electrical system Checking the starting relay Disconnect the starting relay multiple plug Disconnect the negative terminal from the battery and the two wires from the starting relay C D Connect the...

Page 139: ...it is advisable to replace it with one that is known to be in working order or perform a check as shown in the table 1 2 3 4 1 2 3 4 Puntale ROSSO Puntale NERO Corrisponte all indicazione che fornisce il tester quando i terminali ROSSO e NERO non sono in contatto tra di loro Tester per misure fino a 20 000 1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 ...

Page 140: ... information you need to properly operate and maintain your motorcycle The data and specifications provided in this manual does not constitute an engagement on the part of BETAMOTOR S p A BETAMOTOR reserves the right to make any changes and improvements to its models at any moment and without notice ...

Page 141: ...g parts rear sprocket ensure that the footrests are properly fixed front rear brake levers calipers discs check that the plastics are properly fastened engine bolts shock absorber bolts swingarm wheel hubs spokes rear frame pipe connections tensioning the chain IMPORTANT For any servicing requirements please get in contact with Betamotor s authorized service network ...

Page 142: ...arting the engine 106 Refuelling 108 CHAPTER 3 CHECKS AND MAINTENANCE 109 Motor oil level check 110 Motor oil and oil filter substitution 111 Check the level of the front and rear brake fluid and bleeding 114 Check the front and rear brake pads 116 Check the oil level in the hydraulic clutch and bleeding 117 Fork oil 118 Air filter 119 Spark plug 120 Carburetor 121 Coolant 124 Removing the plastic...

Page 143: ...ever 139 Adjusting the handlebars 139 Adjusting the throttle control cable 140 Checking and adjusting the steering play 140 Tensioning the chain 141 Adjusting the headlight 142 CHAPTER 5 REPLACEMENTS 143 Replacing the brake pads front and rear 144 Replacing the headlight bulbs 146 Replacing the rear light bulb 146 Replacing the exhaust pipe 147 CHAPTER 6 TROUBLESHOOTING 149 INDEX 151 ...

Page 144: ...thers always drive carefully and with your helmet on WARNING Any modifications and tampering with the vehicle during the warranty period ex empt the manufacturer from all responsibility and invalidate warranty ECOLOGIC GUIDE Every vehicle powered by an internal combustion engine produces an amount of noise noise pollution and gases air pollution which varies with the riding style The abatement of ...

Page 145: ...sic while riding Never ride abreast with other vehicles Do not tow and avoid being towed by other vehicles Always keep a safe distance from other vehicles Do not sit on the vehicle when it is on its stand Do not start off while the vehicle is on its stand Do not pull out the stand when the vehicle is facing downhill Avoid swaying and wheelies as they are extremely dangerous for your own and other ...

Page 146: ...L INFORMATION 83 GB CONTENTS CHAPTER 1 GENERAL INFORMATION Vehicle identification data Delivery Load Tyres Steering lock Familiarizing with your vehicle Controls Specifications Wiring diagram Electrical devices ...

Page 147: ... data B are stamped in the area shown in the figure WARNING Tampering with the identification numbers is severely punished by law DELIVERY The vehicle is supplied ready for use However it is advisable to conduct a few simple checks before riding Check the tyre pressures Check the oil level in the engine The following items are supplied as stand ard operation and maintenance manual tool kit see pho...

Page 148: ...g of the vehicle To protect your safety immediately re place any damaged tyres Slick tyres adversely affect the road hold ing of the vehicle especially on wet roads and in off road riding Insufficient pressure results in abnormal wear and overheating of the tyres The front and rear tyres must have the same tread design pressure is too high TYRES PRESSION RR 250 400 450 525 TYRE Off road Road Size ...

Page 149: ...try We recommend replacing the tyres at the latest when the tread is 2 mm thick Check the inflating pressure on a regular basis while the tyres are cold Proper pressure ensures optimum riding comfort and prolongs the life of the tyres STEERING LOCK The vehicle is supplied with one key and a spare to be used for the steering lock WARNING Do not keep the spare keys in the vehicle Keep the keys in a ...

Page 150: ... shock absorber 5 Headlight 6 Rear light 7 Side stand 8 Fork 9 Rider s footrests 10 Lower bumper 11 Saddle 12 Engine 13 Front mudguard 14 Number plate holder 15 Kick start 16 Front side panel 17 Rear side panel 18 Fork covers 19 Rear mudguard 20 Lateral bumper 1 2 8 7 9 5 4 6 3 10 11 12 13 16 15 14 17 18 20 19 ...

Page 151: ... to be reduced Ensure that the lever has a play of approximately 10 mm see figure If necessary restore the play see Adjust ments FRONT BRAKE LEVER Front brake lever 3 is fitted to the right hand side of the handlebars Screw B can be used to adjust the home position of the lever see Adjustments GEARCHANGE LEVER Gearchange lever 4 is fitted to the left side of the engine The positions corresponding ...

Page 152: ...h functions 3 TOD T 3 and Vel 0 enables setting of circumference unit and number of pulses for each wheel turn T 3 or Vel 0 cycles through functions 4 TD T 3 resets LAP and TD T 3 cycles through functions 5 COUNTDOWN T 3 and Vel 0 enables setting of countdown T 3 or Vel 0 cycles through functions T Time during which button is pressed down Vel Speed of vehicle DIGITAL SPEEDOMETER CYCLING THROUGH TH...

Page 153: ...turn to the standard operating mode CURRENT SPEED FUNCTION This information is constantly displayed together with an indication provided by a graphic bar The default unit is km h To change the unit press the button to access the Setup menu and select Mph When Mph is selected no indication is provided as to which unit is currently displayed 2 AUTOMATIC LAP FUNCTION LAP T 3 resets LAP and TD T 3 cyc...

Page 154: ...causes the reset of the LAP parameter 5 COUNTDOWN TRIP FUNCTION Countdown T 3 and Vel 0 enables setting of countdown T 3 or Vel 0 cycles through functions This function is always accompanied by a flashing TD caption The counter is al ways active and is automatically decreased by 0 1 kilometres or miles according to the selected unit The value for this parameter can be changed in TD decrease mode b...

Page 155: ...nt receives a signal from the speed sensor The button is depressed As soon as the microcontroller wakes up the following happens The display and the warning lights are checked all the warning lights come up providing that power is supplied by the vehicle for about 2 seconds The selected wheel circumference and number of wheel pulses are displayed for about 2 seconds The last function in use when t...

Page 156: ... indicators if installed When released the lever returns to the central position Press it to turn the indicators off 3 4 2 5 KICKSTART Kickstart 6 is fitted to the right hand side of the engine The upper part of the kickstart can be ori ented SIDE STAND Press down side stand 7 with the foot and lean the vehicle against it Ensure that the ground is solid and the ve hicle stands steadily If the vehi...

Page 157: ...0 mm saddle height 940 mm ground clearance 320 mm footrest height 405 mm DIMENSIONS RR 400 450 525 maximum length 2270 mm maximum width 813 mm overall height 1255 mm wheelbase 1500 mm saddle height 940 mm ground clearance 320 mm footrest height 405 mm FRAME molybdenum steel with double cradle split above exhaust port TYRES pressure bar off road front 1 0 rear 1 0 pressione bar road front 1 5 rear ...

Page 158: ...zocchi hydraulic upside down fork Ø45 mm shafts Oil content in the gearshift fork stem right 610 cc left 610 cc Oil type EB H16 SAE 7 5 Oil level 90 2 mm Trail 108 5 mm front wheel travel 290 mm fork angle 26 5 REAR SUSPENSION Single shock absorber with compound lever shock absorber travel 105 mm rear wheel travel 300 mm FRONT BRAKE Ø255 mm floating disc and dual piston floating caliper REAR BRAKE...

Page 159: ... RR 525 11 1 Carburetor see table Type Keihin FCR MX 37 Keihin FCR MX 39 Keihin FCR MX 39 Keihin FCR MX 39 Carburator setting number 3700A 3900A 3900A 3900B Main jet 160 178 178 178 Jet needle OBEKT OBDVR OBDVR OBDVT Idling jet 42 42 42 42 Main air jet 200 200 200 200 Idling air jet 100 100 100 100 Needle position 3 rd from top 3 rd from top 3 rd from top 3 rd from top Starting jet 85 85 85 85 Mix...

Page 160: ... ZRDK 007 Pinion Z 15 Rear sprocket Z 45 Play of valves intake 0 12 mm exhaust 0 12 mm Ignition DC CDI without trembler with digital variable spark advance Kokusan type Starting electric starter and kickstart Gear ratio 1st gear 14 38 14 34 14 34 14 34 Gear ratio 2st gear 16 36 17 31 17 31 17 31 Gear ratio 3st gear 19 34 19 28 19 28 19 28 Gear ratio 4st gear 21 32 22 26 22 26 22 26 Gear ratio 5st ...

Page 161: ... Bl Bi Bl Ne Gr Gr Ne Bi Ar Bi Ar Ne Ne _ Ne Rs Rs Ne Ve Vi Vi Bi Bi Bl Bl Bl Bi Bl Bl Ro Az Gr Ne Bi Bl Ne Gr Ne Gr B L Gr Ne Gr Ne Gi Rs Gi Rs Gi Rs Ve Bi Ne Gr Bi Ne Ro Ne Bi Ar Bi Ar Gi Gi Ne Ne Ne Ne Ne Ne Ne Ro Az Gr Ne Gr Ne Ve Vi Ma Ne Ro Ne Ne Gr Gi Ve Ne Bl Bi Bl 13 9 14 11 12 17 18 10 Ne 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 29 31 32 33 34 37 35 3...

Page 162: ...0W BULB 17 FLASHER UNIT 18 12V REGULATOR 19 LEFT HAND REAR TURN INDICATOR 12V 10W BULB 20 NUMBER PLATE LIGHT 12V 5W BULB 21 REAR LIGHT 12V 5 21W BULB 22 RIGHT HAND REAR TURN INDICATOR 12V 10W BULB 23 BATTERY POSITIVE TERMINAL 24 BATTERY 12V 5Ah 25 GENERATOR 26 10A FUSE 27 EARTH BRAID 28 STARTER RELAY 29 STARTER MOTOR 30 BATTERY NEGATIVE TERMINAL 31 ELECTRONIC CONTROL UNIT 32 HV COIL 33 SPARK PLUG ...

Page 163: ...y WARNING Extreme caution should be exercised if the electrolyte sulphuric acid should spill out of the battery The electrolyte can cause severe burns In case of contact with the skin rinse generously with water Should the electrolyte come into contact with the eyes rinse with water for at least 15 minutes and immediately seek medical assistance Although the battery is sealed there is a possibilit...

Page 164: ...r horn indicators instrument panel The starting relay also contains spare fuse 7 10 amperes Always replace a blown fuse with another of the same type If the new fuse should also burn out when fitted immediately contact a specialized BETAMOTOR workshop The fuse has a capacity of 10 amperes WARNING Do not on any account fit a larger capac ity fuse or attempt to fix a broken fuse Unskilled operations...

Page 165: ......

Page 166: ...2 OPERATION 103 GB CONTENTS CHAPTER 2 OPERATION Checks to be performed before each ride Recommended lubricants Running in Starting the engine Refuelling ...

Page 167: ...t be as prescribed by law Check the tyre pressure Wear and unsuitable pressure adversely affect road holding 5 BRAKES Check the operation of the brakes and the level of the brake fluid If the brake fluid level falls below the minimum check the brake pads for wear and the brak ing system for possible leaks If an oil leak is found have the braking system overhauled by a specialized BETAMOTOR worksho...

Page 168: ...eed 7 000 rpm 2 For the next 12 hours of operation the engine should only be used to about 75 percent of its power 3 Use the vehicle after properly warming up the engine 4 Avoid travelling at constant speed changing the speed causes the different com ponents to bed in evenly and more quickly WARNING After the first 3 hours or 20 litres of petrol change the engine oil Always use high octane unleade...

Page 169: ...ly and FULLY operate kickstart 3 or use the electric starter WHAT TO DO IF THE ENGINE IS FLOODED After a fall the engine may receive more fuel than is needed In that case pull decompressor lever 4 actuate the kickstart 5 10 times or press the electric starter but ton twice for 5 seconds Subsequently start the engine as described previously If nec essary remove the spark plug and dry it WARNING The...

Page 170: ...d out completely a hole is opened in the carburettor through which the engine can suck in extra fuel This makes it possible to obtain a rich fuel air mixture suitable for cold starting To deactivate the choke push it in to its start ing position 2 ...

Page 171: ...ction of heat It is therefore recommended not to fill the tank to the brim FUEL COCK OFF Fuel cock 3 is closed ON Before using the vehicle turn the knob to ON This allows the fuel to flow to the carburettor When the fuel cock is in the ON position the fuel tank empties until only the reserve fuel is left RES The reserve fuel is used only if the knob is in the RES position Do not forget to bring th...

Page 172: ...ar brake fluid and bleeding Check the front and rear brake pads Check the oil level in the hydraulic clutch and bleeding Fork oil Air filter Spark plug Carburetor Coolant Removing the plastics Drive chain maintenance and wear Suspensions telescopic fork and shock absorber Charging the battery Cleaning and checking the vehicle Scheduled maintenance Prolonged inactivity ...

Page 173: ...remature wear of the engine OIL CIRCUIT Oil pump 3 sucks engine oil from the oil sump through long oil unit 4 Oil pipe 5 conveys the oil to the cylinder head up to camshaft lubrication point 6 The oil quan tity is adjusted by means of oil passage screw 7 An oil pipe branches off towards long oil unit 8 where the coarser particles are filtered out The oil then comes to short oil unit 9 which filter...

Page 174: ...aned and both oil filters replaced The oil must be changed when the engine is at operating temperature WARNING When at operating temperature the en gine and the oil it contains are very hot Take special care to avoid burns Park the motorcycle on level ground re move screw C and let the oil drain in a container Thoroughly clean the screw with a mag net After the oil has drained completely clean the...

Page 175: ...side of the crankcase Push the oil unit in the crankshaft until it stops and then remove the spanner Replace screw 3 and tighten at 15 Nm The oil unit is fitted in a tilted position see diagram To avoid malfunctions be sure to observe this position CLEANING THE SHORT OIL UNIT Short oil unit 1 is inserted in Allen screw 2 on the lower side of the engine Insert an Allen wrench into the screw socket ...

Page 176: ... Insert the long filter unit at the front and the short filter unit at the back of the crank case Grease the oil filter cover O rings and fit covers 4 Fit screws 2 and tighten them at 6 Nm Tighten screw 1 at 8 Nm Remove screw fastener 5 from the clutch cover and pour in 1 25 litres of fully syn thetic engine oil MOTOREX COBRA 15W40 WARNING Before starting the engine it is advisable to rotate the e...

Page 177: ...res special seals and tubes WARNING The brake fluid is extremely corrosive Take care not to spill it on the paintwork BLEEDING THE FRONT BRAKE Follow these steps to bleed the front brake circuit Remove rubber cap B from valve C Remove the oil reservoir cap Insert one end of a small tube into valve C and place the other end in a container Unscrew valve B while pulling the brake lever and then pump ...

Page 178: ...l which re quires special seals and tubes WARNING The brake fluid is extremely corrosive Take care not to spill it on the paintwork BLEEDING THE REAR BRAKE Follow these steps to bleed the rear brake circuit Remove rubber cap E from valve F Unscrew the brake fluid reservoir cap Insert one end of a small tube into valve F and place the other end in a container Unscrew valve F while pulling the lever...

Page 179: ...eplace the brake pads can result in a considerable reduction of the braking action and in damage to the brake disc REAR BRAKE LINING CONTROL Inorder to verify the wear condition of rear brake is enough to view the plincer from the back side where is possible to glimpse the brake lining tails which will have to show a brake of 2 mm in thickness If the stratum is lesser let s start replacing them No...

Page 180: ...LUTCH To bleed the hydraulic clutch first remove the clutch pump cover To do this remove the two screws 1 and take off cover 2 together with the rubber bellows Remove the breather valve from clutch pump cylin der 3 Fit the bleed syringe filled with SAE 10 hydraulic oil in the breather valve socket Pump in oil until it comes out of clutch pump hole 4 with no air bubbles Ensure that no oil overflows...

Page 181: ...p Remove the handlebars after unscrewing the four screws B fixing clevis C Unloosen the stem clamping screws D and E Remove lower plug F and upper plug A pay attention to the spring Let all the oil drain from the rod Replace fork lower plug F Pour in fresh oil of the type shown in the table on page 105 Fit and tighten upper plug A Tighten in sequence first the D screw then the E screw and aging th...

Page 182: ...water Dry the filter Wet the filter with filter oil and then re move the excess oil to prevent it from drip ping WARNING To avoid corroding the filter do not clean it in foam containing petrol or petroleum Never use the vehicle if the air filter is not in place The infiltration of dust and dirt can cause damage and considerable wear If necessary clean the inside of the filter box Replace the filte...

Page 183: ...arry out the check simply remove the current cap and then unscrew the spark plug using the spanner provided Carefully clean the electrodes using a wire brush Blow the spark plug with com pressed air to prevent any residues from getting into the engine Measure the spark gap with a thickness gauge The gap should be 0 6 0 7 mm If the gap is not as specified restore the proper gap by bending the earth...

Page 184: ...xture adjusting screw 2 until it stops then turn it until you obtain the basic adjustment recommended by BETAMOTOR see engine specifications on page 96 Warm up the engine Turn adjusting wheel 1 to obtain the standard idle speed 1400 1500 rpm Slowly turn mixture adjusting screw 2 clockwise until the idle speed begins to lower Remember this position then slowly turn the mixture adjusting screw anti ...

Page 185: ...ll two turns open a larger idling jet is needed Naturally after replacing the jet the adjusting procedure will have to be restarted from the beginning Turn the adjusting wheel until you obtain the desired idle speed The idle speed will have to be adjusted again in case of marked changes in the outside temperature and riding altitude CARBURETTOR WEAR GUIDELINES The throttle valve the needle valve a...

Page 186: ... ing it too hard In this position the float edge should be parallel with the float chamber sealing sur face see figure If the float height does not correspond to the nominal value check the float needle valve and if necessary replace it If the needle valve is in working order adjust the float height by bending float le ver 3 Fit the float chamber install the carburettor and adjust the idle speed 3...

Page 187: ...the engine is cold the radiator fins should be immersed in the liquid for about 10 mm Top up if the coolant does not cover the radiator fins see chart on page 105 The capacity of the circuit is shown in the table on page 95 WARNING To avoid scalds never unscrew the radia tor filler cap when the engine is hot WARNING Fuel is flammable and toxic and must be handled with great care Never work on the ...

Page 188: ...l to remove the bodywork sections as de scribed below Removing the saddle Remove the two fixing screws A one on each side lift the saddle as shown in the figure and pull it off from the back of the vehicle Removing the rear mudguard Remove the two fixing screws B and then the two fixing screws C and D from under the rear mudguard A B C D ...

Page 189: ...ing screws F two on each side and remove the panels The upper screw fixes the saddle as well as the rear panel Removing the right hand side bumper Unscrew the six fixing screws G remove the plastic strap and take off the side bumper if present Removing the left hand side bumper Unscrew the four fixing screws H remove the two plastic straps and take off the side bumper if present E F G H ...

Page 190: ...dguard Remove screw M also located under the mudguard fixing the mudguard backing plate Remove the two mudguard backing fixing screws N from the top of the backing plate Removing the fork covers Unscrew the eight fixing screws P five on the left side and three on the right side and take off the fork covers L M N P ...

Page 191: ...3 CHECKS AND MAINTENANCE 128 GB Removing the headlight fairing Release the two rubber bands Q as shown in the figure pull out the headlight insert and take off fairing R Q R ...

Page 192: ... brake disc otherwise the tyre grip and the action of the brake would be greatly reduced making it very difficult to control the vehicle DRIVE CHAIN WEAR To check the wear of the drive chain use the procedure described below Shift into neutral pull up the upper stretch of the chain with a force of 10 15 kg see figure Measure the length of 18 links on the lower stretch of the chain If the length is...

Page 193: ...pic fork during compression and can be adjusted by means of screw B located at the lower end of the fork legs Turning the screw clock wise increases the action of the compres sion damper turning it anticlockwise de creases the action of the compression damper Standard adjustment 18 clicks from the completely closed posi tion SHOCK ABSORBER ADJUSTING THE HYDRAULIC COMPRES SION DAMPER high and low s...

Page 194: ...se to decrease it After obtaining the desired preload turn counter ring 1 until it stops against adjust ing ring 2 Spring preload 260 mm D C 1 2 3 Low speed adjustment Using a screwdriver loosen screw C by turning it clockwise to decrease the hy draulic compression damper Standard adjustment Screw completely open 21 21 clicks High speed adjustment Turn knob D anticlockwise to decrease the hydrauli...

Page 195: ...voltage 14 4 15 V Charge the battery for about 12 hours Check the voltage 10 12 hours after the end of recharge as described above Constant current Charge battery at 0 5 0 8 A until the voltage between the ter minals stabilizes at 14 5 V WARNING The battery is sealed When recharging it do not remove the seal nor add any liquid WARNING When recharging first connect the battery to the battery charge...

Page 196: ...lute water Always wash the vehicle in areas equipped for collection and purification of the washing liquids Never wash the vehicle in the sun particularly during the summer when the bodywork is hot The shampoo would dry before being rinsed off and cause damage to the paintwork Do not clean the plastic surfaces with cloths soaked in petrol or naphtha as they would lose their shine and mechanical pr...

Page 197: ...ine oil S S Engine oil filter S S Motor oil net filter P P Exhaust pipe bolts T Brakes I I Brake lines replace every 4 years I I Brake fluid replace every 2 years I I Tyres I Steering I I Fork I Rear suspension I Frame nuts bolts and oil tubes T T Chain tension I I I Check and if necessary adjust clean lubricate or replace P Clean S Replace renew T Tighten Note For any service requirements please ...

Page 198: ...e unpainted parts excepting the brakes and the rubber parts with a film of oil or spray silicone Remove the battery and keep it in a dry place Charge the battery every 15 days Protect the vehicle with a dust cover Drain the carburetor float chamber by loosening screw A The fuel drained from the chamber through a suitable pipe must be collected in a container and poured into the fuel tank Do not di...

Page 199: ......

Page 200: ...front lever and brake pedal Adjusting the decompressor lever control cable Adjusting the home position of the clutch lever Adjusting the handlebars Adjusting the throttle control cable Checking and adjusting the steering play Tensioning the chain Adjusting the headlight ...

Page 201: ...E DECOMPRESSOR LEVER CONTROL CABLE Start the engine and let it idle Slowly pull the decompressor lever until you feel the rocker arm knocking The idle travel be fore the knocking is perceived should be approximately 10 mm as measured from the end of the lever If necessary adjust the idle travel using the procedure described below Push back protective cap 8 loosen the counternut and turn adjusting ...

Page 202: ...EBARS The handlebars can be fastened in one of four positions Lower clevis 1 can be positioned on holes 2 and 3 respectively and can be rotated 180 degrees to allow four different adjust ments capable of suiting different driver s requirements Note The fuor positions make it possible to move the handle bar axis as to the vertical axis of the steering wheel 1 2 3 ...

Page 203: ...grip turns smoothly CHECKING AND ADJUSTING THE STEERING PLAY Periodically check the play of the steering head tube by moving the forks backwards and forwards as shown in the figure If any play is felt carry out the adjustment by following these steps Unscrew the five screws 13 Pull out the handlebars paying special attention to the clevises Loosen nut 14 Reduce the play by turning ring To refit th...

Page 204: ...in the chain clean and lu bricated If the chain play exceeds 20 mm tension the chain by following these steps Loosen wheel spindle nut 1 Loosen counternuts A on either side of the fork Turn adjusting screws B on either side until the desired chain tension is obtained Tighten counternuts A on either side of the fork Tighten nut 1 20 mm A B A B 1 ...

Page 205: ...only be adjusted vertically Place the vehicle on level ground but not on the stand 10 metres from a vertical wall Measure the height of the headlight centre above the ground and then draw a cross on the wall at 9 10 of the height of the headlight centre Turn on the low beam get on the motorbike and check that the headlight beam on the wall is slightly lower than the cross drawn previously 10 m 9 1...

Page 206: ...5 REPLACEMENTS 143 GB CONTENTS CHAPTER 5 REPLACEMENTS Replacing the brake pads front and rear Replacing the headlight bulbs Replacing the rear light bulb Replacing the exhaust pipe ...

Page 207: ...o pads as shown in the figure Remove the brake pads taking care not to drop the leaf spring located under the pads To reassemble follow the reverse proce dure When fitting the pads ensure that the leaf spring is properly in place WARNING The brake disc must always be kept free from oil and grease An oily or greasy disc strongly reduces the braking action After work has been carried out on the brak...

Page 208: ...ocated above the two pads To reassemble follow the reverse proce dure When fitting the pads ensure that the leaf spring is properly in place WARNING The brake disc must always be kept free from oil and grease An oily or greasy disc strongly reduces the braking action After work has been carried out on the braking system pull the brake lever to bring the pads into contact with the disc This will al...

Page 209: ...kwise until it stops Replace rubber cap 3 and connector 2 Refit the parking light bulb together with bulb holder 1 If the parking light bulb needs to be re placed simply remove it from the bulb holder and insert the new bulb Reattach the headlight fairing to the sup port pegs and fasten it with the two rubber bands REPLACING THE REAR LIGHT BULB To replace the brake light bulb follow these steps Re...

Page 210: ...i pag 125 Remove the right and the left lateral bumper vedi pag 126 Remove the right back side vedi pag 126 Remove the silencer 1 unscrewing the two fixing screws 2 and the spring 3 united to the exhaust pipe Remove all the four fixing screws 4 two on the right and two on the left of the loom5 Release with a screwdriver the coupling box filter fixing clamp 6 Disconnect the back plant connectors an...

Page 211: ...olt of the damper 7 in order to make it possible for the exhaust pipe to pass Remove the two springs attacked to the cylinder 8 Unscrew the bolt 9 over the lever set in motion and remove the tube running it from the back In order to reassemble it follow the inverted procedure 5 7 8 9 ...

Page 212: ...6 TROUBLESHOOTING 149 GB CONTENTS CHARTER 6 TROUBLESHOOTING INDEX ...

Page 213: ...adjusted Spark plug dirty Restore the spark gap Clean or replace the spark plug Engine knocks Spark advance excessive Carbon formation in cylinder or on spark plug Check the ignition timing Contact a BETAMOTOR dealer Engine overheats and loses power Silencer partly clogged Exhaust port clogged Ignition delayed Contact a BETAMOTOR dealer Contact a BETAMOTOR dealer Check the timing Front braking poo...

Page 214: ...118 Front and rear brake check pads 116 Front and rear brake check the level 114 Handlebars adjustment 139 Recommended lubricants 105 Refuelling 108 Replacing exhaust pipe 147 Replacing the brake pads front and rear 144 Replacing the bulbs 146 Running in 105 Scheduled maintenance 134 Spark plug 120 Specifications 94 Starting 106 Steering check and adjustment 140 Steering lock 86 Suspensions telesc...

Page 215: ...152 ...

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